Feature

Building a Low-Carbon Society

1990
Fujiyama Works

56

November
2023

COLUMN
Cover image:Fujiyama Works
1990

In the late 1980s to the 1990s, Japan experienced a period of
economic boom known as a "bubble economy."
The Fujiyama Works was established to meet the anticipatedincrease in demand for large generators from the Power Systems
Division. With the large manufacturing equipment used in the
Midorigaoka and Tsuiji Works brought in, the Fujiyama Worksbegan operations as a factory with efficient manufacturing
capabilities.
In 2013, it underwent a further expansion, incorporatingstate-of-the-art equipment and efficient automated productionlines. Today, it produces a variety of products, covering all of ourbusinesses̶Cooling Systems, Power Systems, and Servo Systems.
Equipped with a PV generation system, the factory makes gooduse of renewable energy sources and stands as an environmentallyfriendly manufacturing facility.

56
November 2023

SANYO DENKI TECHNICAL REPORT
C

O

N

T

E

N

Building a Low-Carbon Society

TS

Senior Executive Operating Officer Chihiro Nakayama

Feature: Building a Low-Carbon Society

13■ Cooling Systems Division

Building a Low-Carbon Society

Naoki Murakami ................................................................ 3

40 × 40 × 28 mm San Ace 40L 9LG TypeHigh Static Pressure Long Life Fan Atsushi Yanagisawa and Others ......................................... 8
120 × 120 × 25 mm
San Ace 120AD 9AD Type ACDC Fan

Takashi Kawashima and Others .................................... 13■ Power Systems Division

Products and Technology
for a Low-Carbon Society

Masahiko Nagai ............................................................................ 18

The Development of the SANUPS LiB Pack,a Lithium-Ion Battery Pack Mai Saito and Others ........................................................................ 23■ Servo Systems Division

Building a Low-Carbon Society
̶ Energy- and resource-saving initiatives ̶Masahiro Yamaguchi and Others .................................... 27

Development of the SANMOTION C S200
Motion Controller Tatsuya Okazaki and Others ................................................................................ 33

Building a Low-Carbon Society
Chihiro Nakayama Senior Executive Operating Ofﬁcer

In March 2023, as part of its efforts to achieve carbon neutrality, SANYODENKI CO., LTD. set the SANYO DENKI Group’s* medium- to long-term
CO 2 emissions reduction targets: a 46% reduction (from FY 2017) by FY 2030,
and net-zero emissions by FY 2050.
The SANYO DENKI Group is engaged in three types of major initiatives
to achieve a low-carbon society.
The first initiative involves the proactive development of Eco Products. We
are working to reduce the environmental impact and CO 2 emissions of our
products during use by incorporating the latest energy-saving technologies.
The second initiative is for energy savings at our factories. In 1997, weintroduced a PV system to the Technology Center in Ueda, Nagano for the
first time. Presently, the total electricity generation capacity of the entire Ueda
facilities is a maximum of 2,520 kW. In addition, we achieved a significant
reduction in power consumption by replacing all the factory lights by LED
lights. Moreover, the introduction of automation equipment further increased
production efficiency, reducing unnecessary power consumption.
The third initiative is for achieving carbon neutrality. In our Power Systems
Division, we have developed many products that use natural energy, such as
grid management systems and renewable energy inverters for photovoltaic,
wind, and hydroelectric generation systems. We believe that the widespreaduse of our products in the carbon-neutral market will significantly contributeto a low-carbon society.
Among these three, we have been particularly committed to the proactive
development of Eco Products.
Under our corporate philosophy to “aim to help all people achieve
happiness,” the SANYO DENKI Group has developed a number of highefficiency and energy-saving products based on three core technologies:
protecting the global environment, using new energy sources and savingenergy, and protecting people’s health and safety.
* On this matter, the following are applicable: SANYO DENKI CO., LTD., SANYO DENKI
Techno Service CO., LTD., and SANYO DENKI IT Solution CO., LTD.

1SANYO DENKI Technical Report No.56 November 2023

Newly developed products are subjected to comparison with competitors’
products and our existing products. They will be certified as Eco Products
only if our qualification standards are met. The more products that are
certified as Eco Products, the greater our contribution to the environment.
In FY 2022, a total of 20 models were additionally certified as Eco Products,
raising the cumulative total to 358 models.
In FY 2022, the Cooling Systems Division launched a cooling fan that
produces 40% less CO 2 emissions than its predecessor, which was developed
through optimized impeller and frame design and newly developed motor anddrive circuit.
The Servo Systems Division launched a linear servo motor that produces
13% less CO 2 emissions compared to its predecessor by improving the motor’s
winding fill factor to reduce power losses.
In April 2023, the Technology Center in Ueda, Nagano, the research anddevelopment base of Eco Products, shifted to using hydroelectric power named“Shinshu Green Electricity” to further accelerate our initiatives for achievingcarbon neutrality. As a result, combined with its PV generation system, theelectricity used in the Technology Center has been completely shifted torenewable energy, making CO2 emissions from electricity use zero. In this way,the electricity used in the R&D site of Eco Products has been made carbon-free.
Under the feature’s theme of “Building a Low-Carbon Society,” this issue
introduces our products of each business that are aligned with the theme, as
well as technologies based on their roles and features.
The SANYO DENKI Group will continue to contribute to a sustainable
and circular society while achieving both business growth and environmental
protection.

SANYO DENKI Technical Report No.56 November 2023

2

Feature: Building a Low-Carbon Society

Building a Low-Carbon Society
Naoki Murakami

1. Introduction

help improve resource efficiency and reduce waste. These
technologies can contribute to the SDGs shown in Figure 1.

In recent years, global warming and climate change

We believe that low power consumption and long service

have become critical issues worldwide. To realize a “low-life are important qualities of cooling fans. As such, we havecarbon society” with net zero emissions of greenhouse gases,

developed many cooling fans with these features.

including carbon dioxide, which is responsible for theseThis chapter introduces some of the technologies tophenomena, initiatives to reduce emissions are in progress

reduce the power consumption and extend the service life ofaround the world. Efforts include transitioning from gasoline-

cooling fans.

fueled vehicles to electric vehicles, expanding the use of clean
energy, improving energy efficiency, and reducing waste.
A low-carbon society not only contributes to mitigating
global warning and climate change but also is a central
theme of multiple Sustainable Development Goals (SDGs).
Companies, organizations, and individuals around the world
are setting their own goals as they work to achieve a lowcarbon society.
We, SANYO DENKI, are also proactively developing
products to contribute to achieving a low-carbon society
based on our corporate philosophy of “For society andthe natural environment, we will help preserve the global
environment and contribute to the prosperity of mankind
through our corporate activities.”

Fig. 1 The SDGs to which cooling fanswith lower power consumption
and longer service life can contribute

This article introduces technology that reduces power
consumption of cooling fans, as well as our San Ace productsthat contribute to the realization of a low-carbon society.

2.2 Simulation-based automated design
optimization
To lower power consumption in cooling fans, it is essential

3

2. Low Power Consumption and Long
Life Technologies for Achieving
a Low-Carbon Society

for the impeller and frame to demonstrate good aerodynamic

2.1 Fans with lower power consumption
and longer life for a low-carbon society

through trial and error on actual equipment. In recent

performance and for the stator core, windings, magnets, anddrive circuit to provide high efficiency in motor performance.
Conventionally, efficiency improvement used to be achievedyears, however, we have been using simulation-based

Around the world, cooling fans are installed in equipment

design optimization to optimize efficiency. This involves

for a wide range of applications. As such, lowering power

importing the expertise we have accumulated over our past

consumption in cooling fans is an effective means ofdevelopment efforts into simulations for automated design

reducing fossil fuel consumption and curbing greenhouse

optimization. With this approach, we are now able to pursue

gas emissions. Also, cooling fans with longer service life will

even higher efficiency. Figure 2 compares the impeller and

SANYO DENKI Technical Report No.56 November 2023

Building a Low-Carbon Society

frame shapes of our current product and our new 140 × 140

T he i mproved motor ef f iciency a nd aerody na m ic

× 38 mm San Ace 140 9RA type, which was developed using

performance have resulted in significantly lower power

simulation-based automated design optimization. Figure 3

consumption and noise compared to the current product.

compares the power consumption and noise level of them at

2.3 Visualization of airflow

equivalent cooling performance.

To refine the details of the impeller and frame shapes
generated by the aforementioned automated optimization
process, we have been using simulations to visualize airflow.
Unsuitable impeller and frame shapes can cause significant
turbulence and eddies around the impeller blades and frame
spokes, leading to reduced efficiency and elevated noiselevels. Simulation-based visualization of airflow enabled
us to assess the extent of turbulence and eddies, providing
insight into how changes in the impeller and frame shapes
lead to improvements. Figure 4 shows an improvementin eddy reduction through the modification of the frame
spoke’s shape.
Reduced eddy area

New productCurrent productFig. 2 Impeller and frame of the new San Ace 140
9RA type and current product

Spoke

Sound pressure level55

9.5 dB(A)reduction

50
45

We also use simulation-based visualization of airflow
to achieve longer service life. To extend service life, it

40

is effective to use a self-cooling structure that keeps thePower consumption

35

9824% reduction［inchH2O］ ［Pa］

Static pressure

0.4
0.3

100

0.1
0

7
6

Static pressure

580

temperature of the motor and bearing low. The use ofsimulations to visualize the internal airflow has enabled
us to design a structure with an improved self-coolingcapability. Figure 5 shows the visualization of internal
airflow. Compared to Structure A, Structure B has anincreased internal airflow, indicating a better self-coolingcapability.

Estimated
operating
point

60
0.2

After improvement

Fig. 4 Eddy suppression through redesigned
spoke shape

48 VDC

60

Power consumption [W]Sound pressure level [dB(A)]Before improvement

Spoke

Airflow increased

40
20
0

0
0

1

2
50

3
100
Airflow

4

5［m3/min］

150

［CFM］

Current product 109P1448H101
New product 9RA1448H1001

Fig. 3 Characteristics comparison between the
new San Ace 140 9RA type and current product

Structure A

Structure B

Fig. 5 Visualization of internal airflow

SANYO DENKI Technical Report No.56 November 2023

4

Simulation-based automated design and the visualization

longer for the San Ace 9WL type (survival rate of 90%, runof airf low have clarified how the input (parameters

continuously at rated voltage and normal humidity in freeand shapes) affects the output (efficiency and power

air).

consumption). As a result, we can now design impellers,frames, motors, and structures to make cooling fans that
consume less power and last longer.

Table 1 Comparison of the new San Ace 140L
9LG type and current productWe will continue to improve our simulation technology
a nd it s prec ision to develop fa ns w ith even h ig her
performance.

3. San Ace Fans Contributing
to Achieving a Low-Carbon Society

Model no.

Expected
life
[h]

Max.
airflow[m3/min]Max.
staticpressure[Pa]

New product
9LG1412P5G001

180,000

9.0

655

Current product
9LB1412S501

60,0008.1

240

Our San Ace lineup includes Low Power Consumption
Fans, Long Life Fans, and many other products that
contribute to a low-carbon society. This chapter introduces
examples of these products and their features.

3.1 The San Ace 9RA type with low power
consumption and low noise
The San Ace 9RA type, characterized by its low power
consumption and low noise, has been developed as areplacement for our current products: the San Ace 9P, San
Ace 9R, and San Ace 9G types. With sizes ranging from 60

Table 2 Comparison of the new San Ace 140W
9WL type and current product
Model no.

Expected
life
[h]

Max.
airflow[m3/min]Max.
staticpressure[Pa]

New product
9WL1412P5G001

100,000

9.0

655

Current product
9WB1412S501

60,0008.1

240× 60 mm to 140 × 140 mm, the new product consumes lesspower and produces less noise than the current products
while maintaining the same size and cooling performance.
Thanks to its significantly reduced power consumption,
the 140 × 140 × 38 mm San Ace 140 9RA type mentioned

3.3 The San Ace 9AD type ACDC Fan
and the San Ace 9ADW type Splash
Proof ACDC Fan

in section 2.2 produces 41% less CO 2 emissions over

The San Ace 9A D type ACDC Fan incorporates a

its product life cycle compared to the current productDC-powered motor with low power consumption while(according to our LCA calculation software).

operating on AC power, achieving lower power consumption
and an extended service life compared to our current AC fan

5

3.2 The San Ace 9LG type High Airflow
Long Life Fan and the San Ace 9WL typeHigh Airflow Long Life Splash Proof Fanof the equivalent size. It comes with PWM control, a feature
not available in AC fans, enabling fan speed control basedon the operating conditions for further reduction in power

Our lineup offers new fans that boast higher airflow andconsumption. We also offer the San Ace 9ADW type Splash

long service life: the San Ace 9LG type, and the San Ace

Proof ACDC Fan serving as an effective energy-saving

9WL type with water and dust protection. These coolingsolution for various devices requiring AC power input.

fans are ideal for cooling equipment in the renewable energy

Figure 6 compares the power consumption of the ø172 ×

and EV markets, which require both long service life and150 × 51 mm San Ace 172AD 9AD type and 9ADW typewater and dust protection.

with our current product at equivalent cooling performance.

Tables 1 and 2 compare the expected life and general

It shows that the new product consumes 48% less power

specifications of the 140 × 140 × 51 mm San Ace 140L 9LG

than the current product when the fan speed of the new

type and the San Ace 140W 9WL type with our current

product is reduced by PWM control to match the cooling

products, respectively. The San Ace 9LG and San Ace 9WL

performance of the current product (60 Hz). The San

types have 1.1 times the maximum airflow and 2.7 times theAce 172AD has an expected life of 40,000 hours at 60°C

maximum static pressure of the current products. Moreover,(survival rate of 90%, run continuously at rated voltage andthe expected life at an ambient temperature of 60˚C isnormal humidity in free air), which is 1.6 times longer than

three times longer for the San Ace 9LG type and 1.7 times

the current product’s expected life of 25,000 hours.

SANYO DENKI Technical Report No.56 November 2023

Building a Low-Carbon Society

In June 2023, we launched the 120 × 120 × 25 mm San Ace

Equipment

120AD ACDC Fan, the slimmest of our ACDC fans. Details
are covered in a separate article in this Technical Report.
Voltage: 100 VAC
Frequency: 60 Hz

400
New product360

9AD5701P5H003
9ADW5701P5H003

External I/O(Cloud server)

Controller

Terminal

FansInternet

40
Wireless
communication

36

LAN

320

32

280

28

240

Power
consumption

24
48% reduction

200

20

160

16

120

12

80

Settings, control,and monitoring

Power consumption [W]Static pressure [Pa]Current product 109S301

8Staticpressure

40

4
Estimated operating point

0

0

2

4
Airflow [m3/min]

60Fig. 6 Comparison of the new San Ace 172AD
9AD/9ADW types and current products

PC

Data and alarm

DC power supply

Sensors

Fig. 7 San Ace Controller system configuration

4. Conclusion
This article has introduced technologies to lower power
consumption and extend the service life of cooling fans,as well as our San Ace products that contribute to therealization of a low-carbon society.
Achieving a low-carbon society is crucial not only formeeting the SDGs, curbing global warming, and addressing
climate change but also a global imperative. Accordingly,
companies, organizations, and individuals around the world

3.4 Fan controller

are setting their own goals to tackle this global challenge. In

Our lineup also includes the San Ace Controller, an IoT-

addition to our commitment to achieving our environmental

ready fan controller. Figure 7 shows an example system

impact reduction targets, we, as a global manufacturer withconfiguration for the San Ace Controller. The San Aceworldwide product reach, will continue to contribute toController allows PWM fan speed to be optimized, reducing

achieving a low-carbon society by developing and providing

excessive power consumption. Combined with a dedicatedproducts designed for this overarching goal.

sensor, it can provide automatic control of cooling fans.
For instance, with a temperature sensor, it enables theReferencemonitoring of the temperature inside equipment and(1) Masahiro Koike and 4 others: “High Airflow Long Life Fan / High

automatically controls fan speed based on the measurement.

Airflow Long Life Splash Proof Fan San Ace 140L and San Ace

This contributes to maintaining optimal fan speed, leading

140W ”

to a reduction in power consumption.

SANYO DENKI Technical Report No. 46, pp. 7-12 (2018.11)

In addition, as the San Ace Controller can remotely(2) Naoya Ozumi and 4 others: “∅172 × 150 × 51 mm San Ace

monitor the fan speed and current of the cooling fans,

172AD 9AD Type ACDC Fan and San Ace 172AD 9ADW Type

alarms can be issued when necessary. These functions help

Splash Proof ACDC Fan”

users estimate the service life of a cooling fan in its actual

SANYO DENKI Technical Report No. 46, pp. 9-13 (2021.11)

operating environment and perform maintenance at optimal(3) Satoshi Tateyama and 5 others: “140 × 140 × 38 mm San Ace

intervals.

140 9RA type”
SANYO DENKI Technical Report No.55, pp. 9-13 (2023.5)

SANYO DENKI Technical Report No.56 November 2023

6

Building a Low-Carbon Society

AuthorNaoki Murakami
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

7

SANYO DENKI Technical Report No.56 November 2023

New Product Introduction

40 × 40 × 28 mm San Ace 40L 9LG TypeHigh Static Pressure Long Life Fan
Atsushi Yanagisawa

Katsumichi Ishihara

Hikaru Urushimoto

Toshiyuki Nakamura

1. Introduction
ICT equipment is becoming increasingly important insupporting our society and economy. Our Long Life Fanshave been widely used in mission-critical facilities andremotely installed equipment as they require high reliability
and long service life to ensure long-term, reliable operation.
As equipment rapidly advances in performance, it’s
becoming denser and generating more heat, requiring fanswith both high cooling performance and long service life.
To address these needs, we had offered our 40 × 40 × 28 mm

Fig. 1 40 × 40 × 28 mm San Ace 40L 9LG type9L type Long Life Fan (hereafter, “current product”) for awhile. In recent years, however, it has become increasingly

The new product achieves high airf low, high static

more difficult for this fan to meet the latest market

pressure, and long service life while maintaining the same

demands.

size as the current product.

In response, we have developed and launched the San
Ace 40L 9LG type High Static Pressure Long Life Fan

The new product is available in two voltages of 12 and
24 V, while the current product only offers 12 V.

(hereinafter, “new product”).
This article introduces the features and performance ofthe new product.

3. Product Overview
3.1 Dimensions

2. Product Features

Figure 2 shows the dimensions of the new product. The
new product was designed to be compatible in size andFigure 1 shows the appearance of the new product.

mounting with the current product.

28±0.540±0.34±0.3

8-∅3.5±0.3

4±0.3

32±0.332±0.3（10）40±0.3+30
320 0

SANYO DENKI

Rotational direction

Airflow direction

Fig. 2 Dimensions of the San Ace 40L 9LG type (Unit: mm)

SANYO DENKI Technical Report No.56 November 2023

8

3.2 Specifications
3.2.1 General specifications
Table 1 shows the general specifications of the new
product.

Table 1 General specifications of the San Ace 40L 9LG type
Rated
voltage[V]

Model no.

Operatingvoltage
range
[V]

PWM
Rated
duty
current
cycle*
[A]
[%]

Rated
input
[W]

Rated
Max. airﬂow
speed[min-1] [m3/min] [CFM]Sound
OperatingMax. static pressure pressure temperature Expected
life
level
range
[Pa] [inchH2O][h][dB(A)]
[ºC]

100

1.9

22.8

33500

0.93

32.9

1780

7.15

68

20

0.09

1.08

7500

0.2

7.07

89

0.36

33

100

1.23

14.8

28000

0.77

27.2

1290

5.18

65

20

0.07

0.84

5700

0.15

5.3

53

0.21

28

100

0.69

8.28

22500

0.62

21.9

830

3.33

62

9LG0412P3G001

9LG0412P3S001

10.2
to
13.8

12

9LG0412P3H001

9LG0424P3G001

9LG0424P3S001

21.6
to
26.4

24

9LG0424P3H001

20

0.07

0.84

5700

0.15

5.3

53

0.21

28

100

0.95

22.8

33500

0.93

32.9

1780

7.15

68

20

0.07

1.68

6800

0.18

6.36

73

0.29

32

100

0.61

14.6

28000

0.77

27.2

1290

5.18

65

20

0.05

1.2

5000

0.13

4.59

41

0.16

27

100

0.34

8.16

22500

0.62

21.9

830

3.33

62

20

0.05

1.2

5000

0.13

4.59

41

0.16

27

80000
at 60ºC(115000
at 40ºC)
100000at 60ºC(135000
at 40ºC)-20 to +70

80000
at 60ºC(115000
at 40ºC)
100000at 60ºC(135000
at 40ºC)

Speed is 0 min -1 at 0% PWM duty cycle for models without ratings at 0% listed.
Note: The expected life at an ambient temperature of 40ºC is for reference purposes only.

3.2.2 Airflow vs. static pressure
characteristics

3.2.3 PWM control
The new product comes with PWM control for controllingF i g u r e 3 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r e

fan speed.

characteristics of the new product, between different models.

3.3 Expected life
［inchH2O］［Pa］

12/24 VDC

Static pressure

8 2,000
7 1,800
1,600
6
1,400
5 1,200

cooling performance, have an expected life of 80,000 hours
G-speed models
S-speed models
H-speed models

4 1,000
3
2

The new product is available in three speed variations.
G-speed models, the fastest with significantly improved800

at 60ºC (survival rate of 90%, run continuously at rated
voltage and normal humidity in free air). S-speed andH-speed models have improved airflow and static pressure

600

while maintaining the same expected life of 100,000 hours

400

as the current product.

1

200

0

0

図版の文字

0
0

0.2
5

10

0.4

0.6

15

20

0.8
25

30

1［m3/min］
35［CFM］

Airflow

Fig. 3 Airflow vs. static pressure characteristicsof the San Ace 40L 9LG type (different models)

4. Key Points of Development

123

英語版用

Condens

T he new pro duc t ach ieve s fa ster sp e e英語版用
d of up to
Times Ten
33,500 min -1, higher airflow, higher static pressure,andlonger service life, thanks to its highly efficient 3-phasedrive motor,new impeller and frame shapes designed forbetter aerodynamic performance, and effective
and（a）従来品cooling（b）
開発品
heat dissipation.
The key points of development are as follows.

9

SANYO DENKI Technical Report No.56 November 2023

40 × 40 × 28 mm San Ace 40L 9LG Type High Static Pressure Long Life Fan

4.1 Motor design
Achieving higher airflow and static pressure requireda faster speed than the current product. To ensure longer
service life, it was essential to suppress the temperature risein the bearings and improve the motor efficiency. To achievethese, the new product uses a 3-phase drive motor, which issuitable for achieving both high speed and high efficiency,
while a bipolar drive (single-phase full-wave) motor is usedin the current product.
Figure 4 compares the motors of the new and current San
Ace 40L fans.

New productCurrent productFig. 5 Appearance of the newand current products compared
New productCurrent productFig. 4 Motors of the new and current products

4.2 Impeller and frame design
To achieve the impeller’s target durability required for the

5. Comparison of New and Current
Products
5.1 Comparison of airflow
vs. static pressure characteristics

increased fan speed, we leveraged simulations to design an

Figu re 6 compares the ai r f low vs. static pressu re

impeller with improved strength and excellent aerodynamic

characteristics of the new (with different models) andperformance. Also, the impeller has vent holes for better

current products.

heat dissipation of the motor.

The new fastest model, 9LG0412P3G001, has 1.8-times

The frame uses the same aluminum material as the

maximum airflow and 8.7-times higher maximum static

current product for strength and effective heat dissipation.

pressure, compared to the current product. Its expected life

Furthermore, the shape of the stator blades was optimallyis 80,000 hours, which is close to that of the current product,

designed to match the impeller shape.

while significantly improving airflow and static pressure.

Figure 5 compares the impeller and frame shape between
the new and current products.

The new 9LG0412P3S001 model, with the same expected
life of 100,000 hours as the current product, achieves 1.5-times
higher maximum airflow and 6.3-times higher maximum
static pressure.

5.2 Power consumption comparison
Figure 7 compares power consumption between the newand current products at the same airflow.
At t he e st i m ate d system i mp e d a nc e (e qu ipment
ventilation resistance) shown in the figure, the new productconsumes 4 6% less power than the current productdemonstrating a high efficiency.

SANYO DENKI Technical Report No.56 November 2023

10

［inchH2O］［Pa］

Figure 8 compares the CO 2 emissions of the new andMax. 8.7 times

1,800

7

The new product produces 50% less CO2 emissions overits product life cycle compared to the current product thanks6

New 9LG0412P3S001
Expected life 100,000 h

1,400
1,200

to its greatly reduced power consumption.

Current 9L0412J301
Expected life 100,000 h

250
図版の文字

1,000

4

800

3

6.3
times

600
2
400
1

200
1.5 times
0

0

0

0.2

0

0.4
10

0.6

0.8

20
Airflow50

1［m3/min］

0

12 VDC ［W］
4.0［inchH2O］［Pa］

800
3

2

1.5

700

3.5

600

3.0
Power
consumption

500

2.5
2.0
1.5

Staticpressure

1

System impedance

200

046% reduction

400
300

0.5

英語版用

224

Times Ten112（a）従来品
Current
9L0412H301

（b）
開発品

New
9LG0412P3H001

Fig. 8 CO2 emissions comparison using
our LCA calculation software(100,000 hours, when operatingwith the same operating airflow)

6. Conclusion
This article introduced the features and performance of

Estimated
operating
point

100
0
0
0

0.1

0.2
5

0.3

0.4

10

15

the San Ace 40L 9LG type High Static Pressure Long Life
Power consumption

Static pressure

2.5

100

［CFM］

30

50%英語版用
reduction
Condens

150

Max.
1.8 times

Fig. 6 Airflow vs. static pressure characteristicsof the new and current products

1.0
0.5

0.0
0.6［m3/min］

0.5

20

［CFM］

Airflow
New 9LG0412P3G001(at equivalent operating airflow)
Current 9L0412J301

Fig. 7 Power consumption comparison
between the new and current products

11

123

200
CO2 emissions [kg]Static pressure

current products over their life cycles.

New 9LG0412P3G001
Expected life 80,000 h

1,600

5

5.3 Environmental impact comparison

12 VDC

2,000

8

SANYO DENKI Technical Report No.56 November 2023

Fan.
The new product achieves significantly higher airflow andstatic pressure than the current product while maintaining along service life.

図版の文字

123

Furthermore, it is available in 12 and 24 V voltages,
英語版用and this extends the range of applications, contributingtoCondens
improving performance, extending service life, andreducing
英語版用size of various types of equipment.

Times Ten

We will continue to help our customers create newvalue by providing products that promptly address market
demand.

（a）従来品（b）
開発品

40 × 40 × 28 mm San Ace 40L 9LG Type High Static Pressure Long Life Fan

AuthorAtsushi Yanagisawa
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Katsumichi Ishihara
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Hikaru Urushimoto
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Toshiyuki Nakamura
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

SANYO DENKI Technical Report No.56 November 2023

12

New Product Introduction

120 × 120 × 25 mm
San Ace 120AD 9AD Type ACDC Fan
Takashi Kawashima

Naoki Murakami

Sho Furihata

Shuji Miyazawa

Kento Oshima

Masato Murata

Kei Sato

1. Introduction
In recent years, the accelerating trend to a low-carbon
society to combat global warming has led to greater demandfor cooling fans with low power consumption and longservice life. In addition, cooling fans are required to have
PWM control to adjust the fan speed in response to theoperating conditions of equipment as well as a wide input
voltage range for use in various countries.
Since our conventional AC Fans had become unable tomeet these requirements, we have developed and expanded
the lineup of our ACDC Fan, which has a built-in AC-DC
conversion circuit to drive a DC motor.

Fig. 1 120 × 120 × 25 mm San Ace 120AD 9AD type fan

Fu r ther more, for today’s smal ler, more advanced
control panels and industrial equipment, there is anincreasing demand for thin-profile cooling fans, including
ACDC fans, to fit in the reduced and confined spaces.
To meet these requirements, we have developed ourslimmest 25 mm ACDC Fan. This article introduces the

3. Product Overview
3.1 Dimensions
Figure 2 shows the dimensions of the new 120 × 120 ×
25 mm San Ace 120AD 9AD type.

performance and features of the new product, as well as the
key points of development.

2. Product Features

3.2 Specifications
3.2.1 General specifications
Table 1 shows the general specifications of the new product.
The lineup of the product is available in: a high-speed

Figure 1 shows its appearance.

model with PWM control, constant high-speed model,

Its product features are as follows:

medium-speed model, and low-speed model.

(1) Energy savings(2) Long service life

With an operating voltage range of 90 to 264 VAC, they
can be used both with 100 and 200 VAC systems.

(3) Wide operating temperature range(4) High static pressure and high airflow(5) PWM-based fan speed control

3.2.2 Airflow vs. static pressure characteristics
F i g u r e 3 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r echaracteristics of the high-speed, PWM-control model,
9AD1201P4H001. Figure 4 shows the airflow vs. staticpressure characteristics of the high-speed 9AD1201H4002,
m e d i u m - s p e e d 9A D 1 2 0 1 M 4 0 0 2 , a n d l o w - s p e e d
9AD1201L4002 models. The airflow vs. static pressure
characteristics of all new models remain the same over their
input voltage range from 100 to 240 V.

13

SANYO DENKI Technical Report No.56 November 2023

120 × 120 × 25 mm San Ace 120AD 9AD Type ACDC Fan

3.2.3 PWM control

3.3 Expected life

The 9AD1201P4H001 model comes with PWM control
for controlling the fan speed.

The new product has an expected life of 60,000 hours at
60°C (survival rate of 90%, run continuously at rated voltage
and normal humidity in free air).

4×ø4.5±0.3
Mounting holePower lead wires
AWG22
UL11347120±0.8
104.8±0.3

Other lead wires
AWG24
UL1430
+30
300 0

（10）
（5）

104.8±0.3
120±0.8

（5）

+1
25 0

Rotational direction

Airflow direction

Fig. 2 Dimensions of 120 × 120 × 25 mm San Ace 120AD 9AD type fan (Unit: mm)Table 1 General specifications of 120 × 120 × 25 mm San Ace 120AD 9AD type fan
OperatingSound Operating
Max. static
Rated
PWM
Expected
Rated Rated Rated Max. airflow
voltage Frequencypressure temperaturepressure
voltageduty cycle* current input speed
life
range
level
[Hz]
range
[V]
[%]
[h]
[A]
[W] [min-1] [m3/min] [CFM] [Pa] [inchH2O][V][dB(A)][ºC]

Model no.

100

9AD1201P4H001
100
to
240

9AD1201H4002
9AD1201M4002

90
to
264

50/60

9AD1201L4002

0.06

3.4

3000

2.35

83

62

0.249

40

30

0.02

0.7

900

0.7

24.7

6.6

0.03

14

−

0.06

3.4

3000

2.35

83

62

0.249

40

−

0.04

1.6

2250

1.76

62

35

0.140

34

−

0.03

1.1

1800

1.41

49

22

0.088

26

-20 to +70

60000
at 60ºC(90000at 40ºC)* Input PWM frequency: 25 kHz. Speed is 0 min at 0% PWM duty cycle.
Note: The expected life at an ambient temperature of 40°C is for reference purposes only.
-1

100 to 240 VAC, 50/60 Hz

70Static pressure

0.25
0.20
0.15

[inchH2O]
0.30

[Pa]

0.25

PWM duty cycle
100%

60
50
40
30

0.10

PWM duty cycle
30%

20
0.05
0

0.20
0.15

0

20

1

60
9AD1201H4002

50

9AD1201M4002

40

9AD1201L4002

0.10
20

10
0.5

100 to 240 VAC, 50/60 Hz

30

0.05

0

[Pa]
70

Static pressure[inchH2O]
0.30

1.5

40
Airflow

260

2.5 [m3/min]
80

[CFM]

Fig. 3 Airflow vs. static pressure characteristics
of 9AD1201P4H001

0

図版の文

10

123
0.5

0
0

20

1

1.5

40
Airflow

2
60

英語版用

2.5 [m3/min]
80

Condens

[CFM]

英語版用

Times T

Fig. 4 Airflow vs. static pressure characteristicsof new 9AD1201H4002, 9AD1201M4002,
and 9AD1201M4002 models（a）
従来品

SANYO DENKI Technical Report No.56 November 2023

14（

4. Key Points of Development

4.2 Impeller and frame design
The motor needed to be downsized to achieve a thickness

The new product achieves lower power consumption,of 25 mm. In general, however, reducing the motor size

longer service life, higher static pressure, and higher airflow

makes it more difficult to improve the airflow vs. static

while maintaining the same size as our current AC Fan.

pressure characteristics while also suppressing power

The key points of development are as follows.

consumption and heat generation. We addressed this issue
by testing various combinations of parameters such as the

4.1 Design techniques that achieved a 25 mm
thin-profile frame

number, length, angle, and shape of impeller blades as well

ACDC fans need to incorporate a large high-capacitanceon actual equipment to determine the optimal design forcapacitor and, reactor to convert AC input power into low-

as the frame shape through simulations and evaluations
excellent airflow efficiency.

voltage DC power. Figure 5 shows the cross-sectional views

4.3 Low power consumption and longservice lifeof new and current ACDC Fans.
Current ACDC Fan

The new product internally converts AC power into DC

Motor

Impeller boss

Rotor cover

power to drive a DC motor, improving motor efficiency andreducing losses compared to AC motors. With the reduced
power losses and high-efficiency impeller and frame designs
reducing the temperature rise of the motor and bearings, thenew product achieves improved airflow vs. static pressure
characteristics, lower power consumption, and longer
service life compared to our current AC Fans.
図版の文字
Compared to the current product, power consumption
has

Label

been reduced by 72% from 12 W to 3.4 W.

Large components placed on the label side

123

英語版用

The expected life (at 60°C, survival rate of 90%,
Condens run
英語版用continuously at rated voltage and normal humidity
in free

New productTimes Ten

Motor

Impeller boss

Rotor coverair) of the new product is 60,000 hours, 2.4-times longer
than the 25,000 hours of the current product.
（a）従来品（b）
開発品
5. Comparison of New and Current
Products

Label
Large components placed on the impeller side

5.1 Comparison of airflow vs. static pressure
characteristics
Figu re 6 compares the ai r f low vs. static pressu re

Fig. 5 Cross-sectional views of new and conventional
ACDC Fanscharacteristics of the new 9AD1201P4H001 and the current
product. Compared to the current product, the maximum
airflow and maximum static pressure have been improved

W it h ou r c onvent ion a l AC D C f a n s , t he s e l a rge
components were mounted on the label side, which createdunused space inside, leaving little room for downsizing.
To address this, the new product uses a relatively compact
motor for a 120 mm sq. fan, securing space for large
components between the inner surface of the impeller
boss and the rotor cover. This design has helped achieve athickness of 25 mm, making it the slimmest among all of our
ACDC Fans.

15

SANYO DENKI Technical Report No.56 November 2023

by 2% and 19%, respectively. In addition, the operating
airflow has been improved in the actual operating zone.

120 × 120 × 25 mm San Ace 120AD 9AD Type ACDC Fan

0.20
0.15

100 VAC, 60 Hz

70

New 9AD1201P4H001

50
40

0.05

20

Current 109S085

1002% increase

0
0

0.5

1

1.5

20

40
Airflow

2.5 [m3/min]

2
60

81% reduction

Power consumptionof new 9AD1201P4H001

Increased
operating airflow

30
0.10

16
12

19% increase

60

80

[CFM]

Static pressure [Pa]Static pressure

0.25

100 VAC, 60 Hz

Power consumptionof current 109S085[Pa]

Fig. 6 Airflow vs. static pressure characteristicsof the new and current products

8

70

4

60

0

Power consumption [W][inchH2O]
0.30

図版の文

50

123

40
30
20
10

英語版用

Airflow of new
9AD1201P4H001

Condens

英語版用

Estimated
operating point

Times T

Airflow of current
109S085（a）従来品

5.2 Power consumption comparison
with the current product at equivalent
performanceFig u res 7 a nd 8 c ompa re power c onsu mption for

0

0.5

1

1.5

2

2.5

Airflow [m3/min]Fig. 8 Airflow vs. power consumption characteristicsof the new and current products (50 Hz)

the current and new products at equivalent cooling

5.3 Environmental impact comparison

performance.
These figures show that, when the fan speed of the
new product is reduced through PWM control to match

Figure 9 compares the CO 2 emissions of the new andcurrent products over their life cycles.

the cooling performance of the current product, power

The new product produces 77% less CO2 emissions overconsumption at the estimated operating point has been

its product life cycle compared to the current product thanks

reduced by 76% at 60 Hz and 81% at 50 Hz.

to its greatly reduced power consumption.

12

70

76% reduction

8
4
0

60

180
CO2 emissions [kg]Power consumption of current 109S085

Power consumptionof new 9AD1201P4H001

200

16Power consumption [W]

100 VAC, 60 Hz

160
140
120
100
80

77% reduction
183.8 kg

60
40
41.4 kg

Static pressure [Pa]

20
50

0
Airflow of new
9AD1201P4H001

40

20
10

0

図版の文字

New 123
9AD1201P4H001

英語版用

Fig. 9 CO2 emissions comparison using Condens
our LCA
英語版用
calculation software
Times Ten
(operated continuously for 25,000 hours in free air)

Estimated
operating point

30

Current
109S085

Airflow of current
109S085（a）従来品
0.5

1

1.5

2

（b）
開発品

2.5

Airflow [m3/min]Fig. 7 Airflow vs. power consumption characteristicsof the new and current products (60 Hz)

SANYO DENKI Technical Report No.56 November 2023

16（

120 × 120 × 25 mm San Ace 120AD 9AD Type ACDC Fan

6. Conclusion
This article has introduced the features and performanceof our new 120 × 120 × 25 mm San Ace 120AD 9AD type
ACDC Fan equipped with an AC-DC conversion circuit.

AuthorTakashi Kawashima
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

The new product has a built-in AC-DC conversion circuit
and its impeller, frame shape, motor, and circuit are

Naoki Murakami

designed for high efficiency. This realized higher airflow,

Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

higher static pressure, lower power consumption, longer
service life, PWM control, and a wider input voltage range
than our current product.
With the trend toward a low-carbon society accelerating,the demand for products with low power consumption and

Sho Furihata
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

long service life will continue to increase.
We will continue to help our customers create newvalue by providing products that address changing market
demands.

Kei Sato
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Shuji Miyazawa
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Kento Oshima
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

Masato Murata
Design Dept., Cooling Systems Div.
Works on the development and design of cooling fans.

17

SANYO DENKI Technical Report No.56 November 2023

Feature: Building a Low-Carbon Society

Products and Technology for a LowCarbon Society
Masahiko Nagai

1. Introduction
To achieve a low-carbon society, the entire world now
must transition away from the dependence on fossil fuels.
To contribute to this, we have made design efforts bydeveloping products with a higher energy conversion•

Output capacity: 9.9 kW•

DC input voltage range: 150 to 570 VDC•

AC output voltage: 3-phase 3-wire 202 VAC (50/60 Hz)•

Isolated operation output: 3-phase 3-wire 202 VAC, for
9.9 kVA model*(* for grid-connected isolated type only)

efficiency and products that promote the expansion ofrenewable energy.
This article introduces Power Systems products designed
for a low-carbon society and the technologies applied
therein. We begin by describing our power conditioners(or renewable energy inverters) that use renewable energy
along with an implementation example. We then go on to
introduce our energy-saving initiatives for uninterruptible
power supplies (hereinafter, “UPSs”), which protect
mission-critical customer equipment from power outages,
followed by a practical solution.

2. Products That Use Renewable
EnergyRenewable energy has been attracting attention as ameans of reducing the greenhouse gases that cause global

Fig. 1 The SANUPS W73A power conditioner
for wind power and hydro power generation
systems

warming. We offer a lineup of products for using renewableenergy.

In addition, we offer the SA NUPS W75A rectifier
unit, which converts the AC power generated by wind

2.1 Power conditioner for wind powerand hydro power generation systems(1)and hydro power generators into DC power for use withpower conditioners. Featuring protection functions, when

The SANUPS W73A is a power conditioner for windcombined with a power conditioner, the SANUPS W75A

power and hydro power generation systems. It effectively

helps customers build a highly reliable power generation

extracts the energy generated by wind and hydro powersystem with ease.(2) Figure 2 shows a configuration example.

generation systems and feeds it to the power grid. The
SANUPS W73A’s main feature is that its input powercha racter istic s ca n be set f reely to su it the output
characteristics of the customers’ wind and hydroelectric
generators, capitalizing energy from various generators.
Figure 1 shows the SANUPS W73A. Its main electrical
specifications are as follows.

SANYO DENKI Technical Report No.56 November 2023

18

Wind power
generator

The main electrical specifications of the SANUPS P83E

Rectifier unit

are as follows.

Hydroelectric
generator

or other PV inverter
Grid
power

•

Output capacity: 100 kW•

DC input voltage range: 240 to 600 VDC•

AC output voltage: 3-phase 3-wire 202 VAC (50/60 Hz)•

Isolated operation output: 3-phase 3-wire 202 VAC, for
100 kVA model**(** For models with isolated operation)

Fig. 2 Configuration example of the SANUPS W75A
rectifier unit for wind power and hydro power
generation systems

2.3 Renewable図版の文字
energy introduced to our123facilities
英語版用

As a part of ourCondens
low-carbon initiatives, we have PV

2.2 Power conditioners for photovoltaic
generation systems(3)systems installed at several of
facilities and factories.
（bour
）開発品
As the latest example, this section introduces a 300 kW PV

The SANUPS P83E is a power conditioner for photovoltaic

system introduced at the expanded Technology Center ingeneration systems (or PV inverter). The following are two

Ueda, Nagano in May 2021. Figure 4 shows the facility withof its features for effectively extracting the energy generated

solar panels installed on the rooftop.

W75A

by solar panels.

2.2.1 High conversion efficiency
The SANUPS P83E achieves a high conversion efficiencyof 95%, by reducing switching losses and optimizing thetransformer and switching frequency. This allows thegenerated energy to be more capitalized.

2.2.2 Wide AC input voltage range
On the SANUPS P83E, the maximum DC input voltage
has been increased from that of our current product toFig. 4 Solar panels installed on the rooftop of ourTechnology Center

600 V to cover the recent diversified solar panels. The

This PV system uses three units of the aforementioned

increased options for solar panels make it easy to build a high-

SANUPS P83E power conditioner to form a system of

efficiency PV system. Figure 3 shows the SANUPS P83E.

300 kW in total. It generates and powers the facility, and thepower generated in excess can be sold. This system generates
approximately 25% of the power consumed in the facility.
The SANUPS P83E power conditioner features a multiple
unit control function. With multiple unit control, the power
conditioners automatically identify the optimal numberof units to operate according to the amount of power
generated by the solar panels, reducing losses and increasing
efficiency. This multiple unit control function enables highly
efficient operation even when only a small amount of poweris generated, making the most of the energy from the solar
panels.
As an additional feature, in a system of three power
conditioners, with one of them being an isolated operation
model, the system can be used as an emergency powersource during outages using the PV-generated power.

Fig. 3 The SANUPS P83E power conditioner
for photovoltaic generation systems

19

SANYO DENKI Technical Report No.56 November 2023

Products and Technology for a Low-Carbon Society

3. UPS Energy-Saving Efforts

To improve power conversion efficiency, the SANUPS
A11N uses a 3-level inverter circuit. By performing tuning

We of fer var ious types of U PSs to protect public

to match the latest switching semiconductor devices, thisinfrastructure that supports society and mission-criticalproduct achieves a maximum efficiency of 95.1% (94%customer equipment from power outages. The role of aat rated output), which is best-in-class† among UPSs with

UPS is to supply stable power continuously to customer

double conversion online topology on the market. This helps

equipment. Meanwhile, to achieve a low-carbon society,customers reduce running costs and CO2 emissions.

we are also tasked with the important mission of offering
products that contribute to the reduction of CO2 emissions
and reduce the running costs of our customers by further
increasing power conversion efficiency for more energy
savings.

3.2 The SANUPS A23D (5) UPS with highefficiency and functionality
The SANUPS A23D is a double conversion online UPS
featuring high efficiency and high performance. The input/

In the following sections, we introduce some of our efforts
to achieve higher efficiency in our UPSs.

output voltage is 3-phase 3-wire 200 V and can also be set to
210 or 220 V.
Figure 7 shows a 100 kVA model of the SANUPS A23D.

(4)

3.1 The SANUPS A11N UPS with highefficiency and reliability
The SANUPS A11N is a high-efficiency double conversion
online UPS that features reliable parallel redundancy andscalable capacity.
The SANUPS A11N is scalable in a 5 kVA base unit andcan be expanded up to 20 kVA by combining up to fourbase units in parallel. Figures 5 and 6 show models of the
SANUPS A11N.

Fig. 7 The SANUPS A23D UPS, 100 kVA modelFig. 5 The SANUPS A11N UPS, 5 kVA model
The lineup is available in output capacities of 30, 50, 75,
and 100 kVA. The input voltage range is normally 200 V±15% for 200 V output, but if the load level is 60% or less,the UPS can support a wider range with the lower limit
extended to -30%. Accordingly, the UPS maintains inverter
operation without switching to battery power and continues
powering customer equipment even in places with large
power fluctuations.
On the SANUPS A23D, a 2-phase modulation is used in
the rectifier and inverter control system to further improvethe conversion efficiency of our current product. This2-phase modulation stops switching devices sequentiallyin phase order in approximately 1/6 the cycle of the input/

Fig. 6 The SANUPS A11N UPS, 20 kVA model

output frequency, leading to reduced switching loss andimproved efficiency. However, when shifting between the

The input/output voltage can be set to single-phase 200,

switching devices to stop, a large fluctuation will occur at the208, 220, 230, or 240 V, allowing the UPS to be used notneutral point shown in Figure 8. Moreover, if the rectifier

only in Japan but also in global markets.

and inverter control timings are not synchronized, a large

SANYO DENKI Technical Report No.56 November 2023

20

circulating current will flow via the neutral point. These

Device power monitoringand shutdown schedulingfrom PCs

issues will lead to lower efficiency and higher costs due toincreased filter circuit capacity.
With this new product, the 2-phase modulation timings ofLAN

the rectifier and inverter have been synchronized. Also, the2-phase modulation period and AC filter circuit constant
have been optimized. These improvements have reduced
neutral point fluctuations and suppressed circulating
LAN interface
cardcurrent, improving efficiency without additional cost. The
new product achieves an industry-leading††

conversion

efficiency of 94% or higher (max. 95.6%), which suppresses

WLAN USB
dongleUPS

WLAN***

power consumption and heat generation, reducing runningcosts and CO2 emissions.
Device powermonitoringfrom smart phones

Filter circuit
AC
input

RectifierInverterAC
outputNeutral point

DC input(Battery)Fig. 8 Circuit block diagram of the SANUPS A23D

Power supplied/measuredUser equipment

Fig. 9 Proposal example of energy-saving UPS
system solution*** To use wireless LAN, the user will need to prepare a WLAN
USB dongle that we recommended and connect it to the LAN
Interface Card. (USB is a trademark or registered trademark of
USB Implementers Forum.)

It also allows customer equipment connected to the UPS
to be started and stopped remotely. Computers and otherdevices that require a shutdown can be safely stopped after

3.3 Energy-saving UPS system solution

shut down.

The primary role of a UPS is to continuously supply power

I n add ition, the U PS output ca n be schedu led to

to customers’ mission-critical equipment to protect thesystematically start and stop customer devices. For

equipment and its data. At the same time, with the recent

example, devices can be scheduled to stop during the night

expansion of the IoT, the roles of UPSs have also diversified.

or over long holidays for systematic reductions in power

We are developing products to meet various needs beyond

consumption.

the scope of merely a UPS. These demands include server

As described above, UPSs are not only able to protect

power management in the latest security environments andmission-critical customer equipment ↓山洋電気
from power
outages
TR図版用_文字スタイルthe monitoring of power supply conditions, temperature,

but also serve as an energy-saving solution leveraging theand humidity of the operating environment of customer

IoT.

図版の文字

123

equipment.
Against this backdrop, we introduce an example of
our low-carbon efforts—a proposal of an energy-saving
UPS system solution leveraging the IoT. The proposal isillustrated below.
To save energy with equipment, the first thing to know is
how the equipment consumes power. A system combining
our UPS and LAN Interface Card makes it easier tounderstand the power consumption of customer equipment.
Figure 9 shows a configuration example of such a system.

4. Conclusion

英語版用

Condens

英語版用

Times Ten

This article has introduced our Power Systems products
and technologies that contribute to the realization of a lowcarbon society.
The following three products have been presented fortheir use of renewable energy.
(1) The SANUPS W73A power conditioner for wind powerand hydro power generation systems

This system enables the monitoring of equipment power(2) The SANUPS W75A rectifier unit

consumption through a web browser on a smartphone or(3) The SANUPS P83E power conditioner for photovoltaic

computer, visualizing how the data changes over time on agraph for easier understanding.

generation systems
In addition, as an example of our low-carbon initiative,
we have introduced a PV system combining solar panels

21

SANYO DENKI Technical Report No.56 November 2023

Products and Technology for a Low-Carbon Society

and the SANUPS P83E installed in our facilities.
Furthermore, we also described our energy-saving UPS
efforts, including our efficiency improvement technology
and our proposal example of an energy-saving UPS systemsolution.
We are committed to making continual contributions toa low-carbon society by developing technologies for using
and saving renewable energy while continually providing
products that satisfy our customers.
Based on our own market research as of June 2022, conductedamong online UPSs on the market with equivalent voltage,
capacity, and backup time.
††
Based on our own market research as of March 2022,
conducted among online UPSs on the market with equivalent
voltage, capacity, and backup time.
†

Reference(1) Makoto Ishida and 3 others: “Development of the SANUPS W73A
Grid-Connected Isolated Type”
SANYODENKI Technical Report No. 48, pp. 28-32 (2019.11)(2) Ryu Yoshizawa and 3 others: “Development of the SANUPS
W75A Rectifier Unit for Wind Power and Hydro Power Generation
Systems”
SANYODENKI Technical Report No. 50, pp. 24-27 (2020.11)(3) Masahiro Inukai and 8 others: “Development of a 100 kW Power
Conditioner SANUPS P83E”
SANYO DENKI Technical Report No. 37, pp. 19-24 (2014.5)(4) Makoto Kitazawa and 7 others: “Development of the SANUPS
A11N Online UPS”
SANYO DENKI Technical Report No. 54, pp. 29-35 (2022.11)(5) Hiroaki Miyoshi and 8 others: “Development of the SANUPS
A23D Online UPS”
SANYODENKI Technical Report No. 54, pp. 24-28 (2022.11)

AuthorMasahiko Nagai
Design Dept., Power Systems Div.
Works on the development, design, and quality control of power
supplies.

SANYO DENKI Technical Report No.56 November 2023

22

New Product Introduction

The Developmentof the SANUPS LiB Pack,a Lithium-Ion Battery Pack
Mai Saito

Tetsuya Yamazaki

Hidenori Takizawa

1. Introduction

Naoya Nakamura

Kazuya Kudo

life, and high performance. Furthermore, we will also discuss
the advantages of its built-in battery management system.

In general, lithium-ion batteries (LIB) are suitable for2. Product Overview

downsizing thanks to their higher energy density, both byweight and volume, than lead-acid batteries. In addition,s i n c e lithium-ion batteries do not contain substances

Figure 1 shows the SANUPS LiB Pack. Table 1 shows its

such as lead, cadmium, or mercury, they also help reduce

electrical specifications. Its dimensions measure 151 mm wide,

environmental impact at the time of disposal. These features

64.5 mm deep, and 93.1 mm high, with a mass of about 1 kg.

have increased the dema nd for uninter r uptible power
suppl ies (hereinafter, “U PSs”) equipped with lithiumion batteries. It is against this backdrop that we have been
expanding our lineup of UPSs with LIB.
In response to the growing demand, we have in-housedeveloped the SA NUPS LiB Pack, a high-quality, highsafety LIB pack.
In this ar ticle, we begin by presenting the electrical
specif ications, appearance, and circuit block diagram of
the new battery pack. Following that, we will introduce its
features—high safety, high environmental durability, long

Fig. 1 The SANUPS LiB Pack

Table 1 Electrical specifications of the SANUPS LiB Pack
Items

Specifications

Model no.

LFPB12050AU

Cell configuration
Characteristics

Discharge
characteristics

Chargecharacteristics
Ambient temperature

23

Remarks

2P4S (2 parallel 4 series)
Nominal energy

66 Wh

Value at the time of factory shipment

Nominal capacity

5.0 AhValue at the time of factory shipment

Nominal voltage

13.2 V

3.3 V/cell

Discharge cut-off voltage

9.2 V

2.3 V/cell

Recommended discharge current

5A

Maximum discharge current (continuous)

45 A

Maximum discharge current (pulse)

100 A

Charge voltage range

13.8 to 14.4 V

Recommended charge current

2A

At ambient temperature ≥ 0˚C

Recommended charge current

0.5 A

At ambient temperature < 0˚CMaximum charge current (continuous)

10 A

At ambient temperature ≥ 15˚C

In operation-20 to +60°C

Dimensions

151 × 64.5 × 93.1 mm

Mass

Approx. 1 kg

Standards

UL 1973

SANYO DENKI Technical Report No.56 November 2023

Pulse duration 100 ms

Width × depth × height, excluding protruding parts

The Development of the SANUPS LiB Pack , a Lithium-Ion Battery Pack

Protection circuit
Fuse

Battery
monitoringIC

Temperature
sensorTemperature
sensorCircuit breaker

Battery
monitoringIC

LiB cell
2P4S

Current
sensorCircuit breaker

Fig. 2 Circuit block diagram of the battery packFigure 2 shows the circuit block diagram of the battery

図版の文字 of theTable 2 shows the built-in protection functions

123

pack. The battery pack has a nominal voltage of 13.2 V andbattery pack.

a nominal capacity of 5 Ah. Its LIB cells use lithium iron

* UL 1973 is the UL standard for Batteries forCondens
Use in Stationary
and Motive Auxiliary Power Applications.

phosphate in the cathode material and are connected in a

英語版用

英語版用

Times Ten

2-parallel 4-series (2P4S) configuration. It employs built-in
protection circuits to monitor and protect the battery cells.
Up to four battery cells can be connected in series without

Table 2 Protection functions

an external battery management system.

Protection
functions

Functions explained

3. Features

Overcharge
protection

This function detects overcharge
in cell voltages and shuts off thecharging circuit.

3.1 High safety(1)Overdischarge
protection

This function detects overdischarge
in cell voltages and shuts off thedischarging circuit.

Overcurrent
charging
protection

This function detects overcurrent
charging and shuts off the charging
circuit.

Overcurrent
discharging
protection

This function detects overcurrent
discharging and shuts off thedischarging circuit.

High-temperature
protection

This function detects hightemperatures in batteries and shuts
off the charging/discharging circuit.

Low-temperature
protection

This function detects low
temperatures in batteries and shuts
off the charging/discharging circuit.

Due to its high energ y density, LIBs could potentiallycause serious accidents if mishandled. Ensuring safety is of
the utmost importance.
To ensure a high level of safety, we devised and applied tothe battery pack the following three measures.
(1) Use of iron phosphate battery cells(2) Protection circuits with a circuit breaker(3) Full redundancy of each protection circuit（a）従来品（b）
開発品

The battery cells in this product use lithium iron phosphatein the cathode material, featuring high thermal stability andelectrolyte stability. Therefore, even in the event of battery
pack malfunctions, such as overcharge and overdischarge,
the risk of explosion or ignition is extremely low.

3.2 High environmental durability
The lead-acid batteries currently used in our UPSs havean operating temperature range of -20˚C to 50˚C during

The protection circuits come with a circuit breaker. Upon

discharge and 0˚C to 40˚C during charging. In contrast,

detecting a malfunction, such as overcurrent, overcharge,

that of the new battery pack is -20˚C to 60˚C, enabling theand overdischarge in the battery pack, the built-in circuit

UPS to be used at an extended temperature range. Thisbrea ker is act ivated a nd protects t he bat ter y pack bymeans UPSs combined with this battery pack can be used in

shutting off the charging/discharging circuit. In the caseharsher environments than lead-acid battery UPSs.

of an accidental short circuit of a terminal, the protection
circuit will likewise be activated and prevent the short-circuitcurrent from flowing, ensuring safety.

3.3 Long life
Figure 3 shows the estimated cycle life of the batter yFurthermore, as each protection circuit is fully redundant,

pack . The bat ter y pack ma i nta i ns 8 0% or more of its

the backup circuit will provide protection even if one circuit

capacit y even af ter 3,800 charge/discharge cycles at an

fails. (UL1973-certified*)ambient temperature of 30˚C. When used at a rate of one

SANYO DENKI Technical Report No.56 November 2023

24

15

approximately 10 years. In contrast, when used at the same

14

rate, the lead-acid batteries used in our conventional UPSs
require battery replacement around every six months. As
it lasts longer than lead-acid batteries, the batter y pack5
helps realize maintenance-free operation図of
equipment andreduce replacement costs.

Voltage [V]charge/discharge cycle a day, it can be expected to last

13

1C

0.2C

12
11
10

Note: Battery service life may vary depending on the operating
environment and operating conditions.

2C

0

1000

2000
3000
4000
Battery capacity [mAh]

5000

6000

Fig. 5 Charge characteristics

100

Capacity [% BOL]

20˚C
95

30˚C

3.5 Built-in battery management system

40˚C

To be used safely, LIBs must be used in combination with

50˚C

90

a battery management system for monitoring the battery
status and providing protection. This LIB battery pack has

85

a built-in battery management system with features such ascell voltage monitoring and circuit protection. Therefore,

80
0

1000

2000

3000

4000

the batter y pack can be readily used without requiring

5000

an external batter y management system. Moreover, theCycle count [cycles]

S A N U PS Li B Pack ca n read i ly replace t he bat ter y ofFig. 3 Estimated cycle life (calculated)existing lead-acid batter y UPSs, which do not require abattery management system.

3.4 High performance
Fi g u r e 4 s how s t he d i s c h a r g i n g c h a r ac te r i s t ic s ofthe batter y pack a nd Fig ure 5 shows the cha rg ing

4. Conclusion

characteristics. The new battery pack allows rapid charging

This article provided an over view and features of theand discharging, featuring a maximum charge and discharge

SA NUPS LiB Pack, a lithium-ion battery pack we newly

current of 2C (10 A) and 9C (45 A), respectively, making

developed. The features of the product are as follows.

it ideal for applications requiring large current output.
Furthermore, being capable of rapid charging, it is suitable(1) High safety

for use in equipment that requires frequent charging and(2) High environmental durability

discharging such as automated guided vehicles (AGVs).

(3) Long life

Its shor t charg ing time reduces equipment dow ntime,(4) High performance

improving operational efficiency.

(5) Built-in battery management system

Note: The C - rate is a measure of the rate at which a batter y ischarged or discharged, with a 1C rate defined as the current
that completes the charge/discharge of the entire battery in
one hour.

With the SANUPS LiB Pack, with the above-mentioned
advantages, developed successfully, we can now offer highquality, high-safety UPSs to the increasingly demanded LIB
UPS market.

15

Voltage [V]

14

0.2C

13

Besides use in UPSs, this batter y pack is also suitable
for a wide range of applications that have traditionally

1C
3C

relied on lead-acid batteries, including automated guided

12
9C

11

t he needs of a d iver se ra nge of customer s, ser v i ng as
0

1000

2000

3000

4000

5000

Battery capacity [mAh]

Fig. 4 Discharge characteristics

25

equipment, and power supply equipment.
We are confident that the SANUPS LiB Pack can meet

10
9vehicles (AGVs), power backup systems for communications

SANYO DENKI Technical Report No.56 November 2023

6000

a compac t, l ig ht weig ht, sa fe, h ig h-per for ma nce, a ndenvironmentally friendly solution.

The Development of the SANUPS LiB Pack , a Lithium-Ion Battery Pack

Reference(1) Tobishima, Shinichi:

Safety and Elemental Technologies for

Lithium Ion Batteries (Design Technology Series),[Translated

from Japanese.], Kagakujyoho shuppan Co., Ltd. (2016.10)

AuthorMai Saito
Design Dept., Power Systems Div.
Works on the development and design of power supplies
products.

Tetsuya Yamazaki
Design Dept., Power Systems Div.
Works on the mechanical design of power supplies.

Hidenori Takizawa
Design Dept., Power Systems Div.
Works on the mechanical design of power supplies.

Naoya Nakamura
Design Dept., Power Systems Div.
Works on the development and design of power supplies
products.

Kazuya Kudo
Design Dept., Power Systems Div.
Works on the development and design of power supplies
products.

SANYO DENKI Technical Report No.56 November 2023

26

Feature: Building a Low-Carbon Society

Building a Low-Carbon Society

̶Energy- and resource-saving initiatives̶
Masahiro Yamaguchi

Tsuyoshi Kobayashi

Akira Tsukada

Takahiro Yoneta

Yasushi Misawa

1. Introduction

The SANMOTION G AC servo system, which we launchedin May 2022, features a higher energy conversion efficiency

In recent years, the increasing impact of global warming

than its predecessor and is one of our low-carbon products.

and the natural disasters caused by climate change haveThis section introduces the SANMOTION G’s servo motors.

brought the urgent need to realize a low-carbon society.
We, SANYO DENKI, have been engaged in initiatives

2.1.1 The SANMOTION G servo motorsof “technology for protecting the global environment” andWe pursue compactness, light weight, and high efficiency“technology for saving energy,” and developed and offeredi n t h e d e ve l o p m e n t o f s e r vo m o t o r s . T h e l a t e s tvarious Servo Systems products aligned with them. In our

SANMOTION G servo system not only achieves improved

production sites, we have made consistent efforts such as

servo performance than its predecessor, the SANMOTION

reducing power and raw material usage.

R servo system, but is also environmentally friendly.

This article introduces Servo Systems products andFigure 1 shows the SANMOTION G servo motor andtechnologies that contribute to energy and resource

amplifier. The following sebsections describe the features ofconservation with the aim of realizing a low-carbon society.

the servo motor, as well as our energy-saving and industrial

It also introduces the energy-saving technologies andwaste reduction initiatives related to it.

the 3 R’s initiatives (Reduce, Reuse, and Recycle) in our
production.

2. Products and Technologies
for Achieving Low-Carbon Society
This chapter introduces our products and technologies
that contribute to a low-carbon society.
Fi rst, rega rd ng ou r ser vo motors, we present thefeatures of the SANMOTION G servo motor, which ismore compact, lightweight, and energy-efficient thanits predecessor. Next, regarding our servo amplifiers,
we present the SANMOTION G servo amplifier, whichboasts significantly reduced CO2 emissions compared to its
predecessor, as well as a power regeneration device, which(a) Servo motor(GAM2A6040F0XRK0)(b) Servo amplifier(GADSA02AH24)

Fig. 1 The SANMOTION G servo system

contributes to the effective use of electricity.

2.1 Servo motor and technology

27(1) Reduced size and weight, increased output,
and resource savings

Servo motors are energy conversion devices that convert

For the SANMOTION G servo motor, we have optimized

electrical energy into mechanical energy. To contributethe electromagnetic field design and winding of the motor

to a low-carbon society, it is crucial that the conversion

unit and holding brake. Moreover, improvements have beenof electrical energy into mechanical energy is done more

made to the connector arrangement and motor construction,

efficiently.

and the size of the encoder has been reduced, significantly

SANYO DENKI Technical Report No.56 November 2023

Building a Low-Carbon Society ̶ Energy- and resource-saving initiatives ̶shortening the motor length. Figure 2 compares the lengths

substantial reductions in CO2 emissions, achieving up to aof the motors. With the SANMOTION R’s high torque and48.3% decrease.(1) In this way, the product contributes morehigh power maintained, the new motors have been madeto achieving a low-carbon society than the current product.
Table 1 shows the LCA results of servo motors, presenting

volume of the servo motor components has been reduced by

a comparison of energy usage and CO2 emissions between

up to 28%, saving resources.

the current SANMOTION R and the new SANMOTION G.

Low inertia

up to 22% shorter and up to 26% lighter. As a result, the40 mm sq., 100 W

-9%
-6%

80 mm sq., 750 W
100 mm sq., 1.5 kW

The built-in encoder is a high-resolution battery-less-7%

absolute encoder with a maximum resolution of 27 bits. The-18%

40 mm sq., 100 W
Medium inertia(3) Higher encoder resolution and reduced
industrial waste-9%60 mm sq., 400 W

high resolution enables stable repetitive motion and high--19%

60 mm sq., 400 W-22%

80 mm sq., 750 W

precision positioning. This encoder eliminates the need

86 mm sq., 1 kW

-15%

100 mm sq., 1 kW

-11%

130 mm sq., 1.2 kW
0

-8%
100
150
Motor length [mm]SANMOTION R
SANMOTION G
50

for battery backup for retaining multi-turn data when the
power is turned off. Consequently, there are no batteries
200that need to be periodically replaced, contributing to natural
resource saving, reduced industrial waste, and improved
図版の文字

maintainability.

Fig. 2 Motor length comparison

123

英語版用

Condens

2.2 Servo amplifier and technology
英語版用(2) Increased energy efficiency

Ten highServo amplifiers have been required toTimes
have:

Although there is a trade-off between shortening theefficiency conversion technology, effective use of energy,

motor length and improving efficiency, we achieved reduced

and motion control technology linked with the IoT (Internet

power loss and up to 9% higher efficiency by optimizing theof Things) technology and AI (artificial intelligence) toelectromagnetic field design as mentioned earlier, improving

share information with and manage machinery.

（a）従来品（b）
開発品

the winding fill factor, and using low-loss materials.

In the following subsections, we present two low-carbon

Furthermore, for the holding brake, we have optimized

products: the SANMOTION G servo amplifier, which emits

the electromagnetic field design and structure, along withless CO 2 than its predecessor; and a power regeneration

improvements in the winding fill factor, achieving up to 44%

device, which makes effective use of the regenerative power

lower power consumption. In addition, current consumption

from servo motors.

of the encoder has been reduced by 26% compared to ourcurrent product. It was eco-designed and features highefficiency and energy savings.

2.2.1 The SANMOTION G servo amplifiers
When developing a new servo amplifier, we aim to achieve

T ha n ks to these ef for ts, based on the Li fe C ycle

a weight reduction and higher energy conversion efficiency.

A ssessment (L CA), the new product demonstrates

In order for the SANMOTION G servo amplifier to have

Table 1 LCA results of servo motors
LCA results

Energy usage

CO2 emissions

Size

Rated output

SANMOTION R (R2)
(Current product)

SANMOTION G (GAM2)(New product)

Reduced by

40 mm sq.

100 W

1,727 Mcal

1,643 Mcal

4.8%

60 mm sq.

400 W

2,728 Mcal

2,575 Mcal

5.6%

80 mm sq.

750 W

4,347 Mcal

3,401 Mcal

21.8%

100 mm sq.

1 kW

4,382 Mcal

3,374 Mcal

23.0%

130 mm sq.

1.2 kW

10,585 Mcal

5,443 Mcal

48.6%

40 mm sq.

100 W

447 kg

426 kg

4.8%

60 mm sq.

400 W

706 kg

670 kg5.1%

80 mm sq.

750 W

1,127 kg

881 kg21.8%

100 mm sq.

1 kW

1,141 kg

877 kg23.1%

130 mm sq.

1.2 kW

2,739 kg

1,416 kg

48.3%

SANYO DENKI Technical Report No.56 November 2023

28

Table 2 LCA results of servo amplifiers
LCA results

Amplifier capacity
10 A

Energy usage

20 A
30 A
50 A

CO2 emissions

SANMOTION R 3E Model(Current product)

SANMOTION G(New product)

Reduced by

905 Mcal

736 Mcal

18.7%

2,412 Mcal

2,259 Mcal

6.3%

3,797 Mcal

3,654 Mcal

3.8%

6,257 Mcal

5,826 Mcal

6.9%

10 A

233 kg

189 kg

18.9%

20 A

638 kg602 kg5.6%

30 A

1,000 kg

963 kg3.7%

50 A

1,630 kg

1,520 kg

6.7%

an improved power density, we have improved the maximum

Recently, we have developed a product equ ipped

output current by up to 5% by using a power semiconductor

with the power regeneration capabilities to effectively

device with low heat generation and optimizing the thermal

use regenerative power, and this is used by many of ourdesign. Moreover, we selected and used components that

customers. Figure 3 shows an example configuration of ahave low current consumption ratings, reducing the total

power regeneration device.

power consumption by up to 22%. At the same time, theselected components are also smaller in size, achieving aPower regeneration device

weight reduction of up to 5.5%.
Compared based on Life Cycle Assessment (LCA) using
these values in the calculation, it can be said that the newACreactorConverterPower
supplySmoothingcapacitor

Regenerative
power

InverterInverterproduct produces up to 18.9% less(1) CO 2 emissions thanthe current product, contributing to achieving a low-carbon
society.
Table 2 shows the LCA results of servo amplifiers,
providing a comparison of energy usage and CO2 emissions
between the current SANMOTION R 3E Model and new
SANMOTION G amplifiers.

Phase
detection
Current
detection
Voltagedetection

Servo
motor
Gate
control

Fig. 3 Power regeneration device

The servo amplifiers feature the monitoring of power

A power regeneration device comprises a converter

consumption of servo systems by calculating the data

featuring an IGBT bridge with a free-wheeling diode. This

collected from sensors. By displaying the electricity

circuit is designed for both forward and reverse power

consumption status to customers who use our servo systems,

conversion. The regenerative power generated by the servo

this feature can contribute to the efficient use of electricity,

motor flows through the inverter and charges the smoothingboth in machinery and across entire factories.

capacitor. Subsequently, the energy is fed back to the power
grid through reverse conversion by the converter.

2.2.2 Power regeneration device

current method,(2) which involves detecting the phase of thethe most when powering a motor to drive a load equipment.

power supply voltage and only regenerates power in 120°

On the other hand, however, when decelerating or comingintervals of the power supply voltage. With this method,

to a halt during motion, the load applied to the motor acts inthe frequency of IGBT switching is much smaller than

the reverse direction of the driving force, causing the motorthat of the PWM method, resulting in minimized loss andto function as a generator.

leakage current. In this way, the power regeneration method

Conventionally, the regenerative power generated usedavoids converting the regenerative power into wasted heat.

to be for the most part dissipated as heat through resistors,

Unlike the regenerative resistor method, it can be used morea process we refer to as the regenerative resistor method.

effectively as energy for other machinery.

However, electricity cannot be used effectively with thismethod.

29

The control method of power regeneration is the 120°

Systems that are used for machinery consume electricity

SANYO DENKI Technical Report No.56 November 2023

Building a Low-Carbon Society ̶ Energy- and resource-saving initiatives ̶

The power regeneration technology in products results

Modifications were made to adjust the discharge flow

in lower losses and reduced power consumption. This notrate by controlling the pump operation using the inverter

only enables the efficient use of energy but also significantly

installed for the drive motor of the pump, leading to acontributes to the realization of a low-carbon society.

reduction in power consumption.
This improvement has resulted in significant energy

3. Low-Carbon Initiatives in Productionsavings by controlling the pump operation, which used

This chapter introduces examples of our energy-saving

drive motor. Power consumption of the rinsing process

and waste-reduction initiatives in production. It firstwas reduced to approximately 1/2 compared to before thepresents energy-saving technologies for the electroplating

improvement.

to be at full capacity all the time, through control of thel i ne a nd t he b ond i ng pro c e s s a s i n it iat ive s i n t he
manufacturing processes. Then, it introduces examples of
the 3 R’s (Reduce, Reuse, and Recycle) efforts as initiatives
on our production sites.

3.1.2 Energy-saving technology in the magnet
bonding process (from heating furnace
to high-frequency induction heater)
Along with the new SANMOTION G servo motors, we

3.1 Energy-saving technology in production
processes

also developed a new magnet bonding unit.
T h is u n it u ses h ig h-f requency i nduct ion heat i ng

We put quite an energy-saving design effort when revisingtechnology to accelerate the thermal curing of the adhesive

our existing manufacturing equipment and developing

to bond the magnets to the rotor to achieve greatly reduced

new equipment. This section highlights examples of ourpower consumption.

initiatives in the electroplating line as an improvement ofexisting equipment, and energy-saving technology in the

Figure 5 illustrates the principle behind high-frequency
induction heating technology.

newly developed magnet bonding unit.

3.1.1 Energy-saving initiative in electroplatingline
The electroplating line includes a rinsing process that

High-frequency
current
High-frequency
magnetic flux

sprays water to clean products. Figure 4 shows the rinsing
process of the electroplating line. During rinsing, thedischarge flow rate must be adjusted to prevent workpieces
from falling or water from splashing due to the water

Induction coilpressure. Before improving the equipment, the pump
operation of drawing water up from the tank used to beworking at full capacity at all times, and workers had
to manually adjust the flow rate with a regulator valve,

Heated workpiece

resulting in wasted power.

Fig. 5 High-frequency induction heater illustrated
Electroplating line

Water spray process

In the magnet bonding process for the current product, adrying oven is used for thermal curing of the adhesive. The
Rinsing process

drying oven needs to maintain the heating temperature,
which requires the heater to be left turned on from the
beginning to the end of the operation regardless of whether
workpieces are present, continuously consuming power.
The high-frequency induction heating technology used forthe newly developed unit allows quick heating of workpieces

Fig. 4 Rinsing process of electroplating line

and consumes power only during the heating process. This
has led to a significant reduction in power consumption
compared to the drying oven. The power consumption per

SANYO DENKI Technical Report No.56 November 2023

30

rotor has been reduced to approximately one-third that ofthe drying oven method.

3.2 The 3 R’s in production
At the production sites of Servo Systems products, weare promoting the principles of the 3 R’s (Reduce, Reuse,
and Recycle). These principles guide our behaviors,
aiming to mitigate environmental impact and facilitate thecapitalization of resources. This section introduces specificexamples of the initiatives.

3.2.1 The “Reduce” initiative

Fig. 7 Plastic containers for electronic components

3.2.3 The “Recycle” initiative

We are promoting an initiative to change the packaging

We promote material recycling by selling expired solder

mater ia ls for del iver i ng Ser vo Systems products togenerated in the PCB manufacturing process and solder

customers, replacing corrugated cardboard boxes withscrap oxidized in manufacturing processes to waste

reusable, returnable boxes, as shown in Figure 6. The

recyclers. Figure 8 illustrates the flow of solder scrap

use of returnable boxes reduces the energy required forrecycling. Recycling valuable mineral resources such as

the production of corrugated cardboard boxes and thetin and silver contained in solder makes consumption andconsumption of forest resources.

production more sustainable. It also reduces the need tomine for new mineral resources, reducing the impact on the

ing
er

So
ld
e

p
cra
rs

So
ld

global environment and ecosystems.

t

3.2.2 The “Reuse” initiative
To promote resource circulation by reducing and recycling
plastic waste, the Plastic Resource Circulation Act was

m

od

uc

at

Pr

Fig. 6 Returnable delivery boxes for servo
amplifiers

io nRecycling
solder scrap

Re

cla

Fig. 8 Flow of solder scrap recycling

enacted in April 2022.
Our Servo Systems Division promotes the sustainable useof resources by returning plastic containers for electronic

4. Conclusioncomponents, as shown in Figure 7, to the manufacturer forThis article has introduced Servo Systems products

reuse. The reuse of plastic containers also helps component

and technologies that contribute to the reduction of CO 2

manufacturers avoid procurement risks such as soaring resin

emissions by saving resources and energy to achieve a low-material prices and material shortages.

carbon society. It has also presented the electroplating line
and the magnet bonding unit as examples of energy-saving
technologies in the production processes. Furthermore,
it has introduced examples of the 3 R’s initiatives at our
production sites.
The SANMOTION G servo motors and amplifiers, which

31

SANYO DENKI Technical Report No.56 November 2023

Building a Low-Carbon Society ̶ Energy- and resource-saving initiatives ̶are compact and lightweight, contribute to energy andAuthorresource savings thanks to their high conversion efficiency.
The power regeneration device achieves power savings by

Masahiro Yamaguchi

effectively supplying the regenerative power of motors to

Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

other machinery.
The electroplating line reduces power consumption bycontrolling pump operations in the rinsing process. In

Tsuyoshi Kobayashi

the magnet bonding process, use of the high-frequency

Design Dept. 2, Servo Systems Div.
Works on the development and design of servo ampliﬁers.

induction heating technology has achieved reductions in
production time and power consumption.
In the 3 R’s initiatives in production, we have reduced ourenvironmental impact by using returnable boxes to reduce
the use of corrugated cardboard boxes, reusing plastic

Yasushi Misawa
Design Dept. 1, Servo Systems Div.
Works on the development and design of servo motors.

containers, and recycling solder scraps.
In the future, expectations for servo system technologies
that contribute to a low-carbon society are anticipatedto grow even higher. We intend for our servo systems tocontinue to meet these expectations and protect the global

Akira Tsukada
Production Dept. 2, Servo Systems Div.
Works on the production of motion controllers and servo
ampliﬁers.

environment and human life.

Takahiro Yoneta
Reference(1) Yasushi Misawa and 15 others: “Development of SANMOTION GAC Servo Systems”

Production Engineering Dept., Servo Systems Div.
Works on the production engineering of servo motors andstepping motors.

SANYO DENKI Technical Report No. 54 pp. 42–51 (2022.11)(2) Yuji Ide and 5 others: “Servo Amplifier Technology Contributing
to Effective Use of Power”
SANYO DENKI Technical Report No. 34 pp. 12–15 (2012.11)

SANYO DENKI Technical Report No.56 November 2023

32

New Product Introduction

Development of the SANMOTION C
S200 Motion Controller
Tatsuya OkazakiTomonobu Tazaki

Hiroto Endo

Yoshitaka Kobayashi

Hyukjun Kwon

Shigeki Sato

1. Introduction

Masayuki Mizutani

It comes with a DIN rail(1) for easy installation on a control
panel.

In recent years, IoT technologies have been increasingly
used in various industries to improve productivity andquality. To ensure efficient, stable production, motion
controllers must be capable of detecting changes in the(1) DIN stands for Deutsche Industrie Norm (German Institute forStandardization). The DIN rail is a metal rail that conforms tothis standard.

operating status and the ambient environment of equipment
to allow users to monitor the conditions of production sites.
Controllers are also required to collect and store real-timeerror data in the event of a failure to minimize recovery time.

55

Against this backdrop, we developed a motion controller

110
DIN railthat accurately monitors the operating status of equipment
This article introduces the main functions and features of120

and enables users to remotely perform maintenance.
the SANMOTION C S200 (hereinafter, “new product”)—

2. Product Overview

12

the latest addition to the SANMOTION C motion controller
lineup.

Fig. 2 Dimensions of the new product (Unit: mm)

2.1 External view
Figure 1 shows the new product and Figure 2 shows its
external dimensions.

2.2 Specifications
Table 1 shows the product lineup and general specifications,and Figure 3 shows a system configuration example.
The new product is available in two models: an advanced
model for complex interpolation control and a basic model
specialized in PTP (Point-to-Point) positioning control.
Both models support EtherCAT (as master), Ethernet,
RS-485, and 1-Wire(2) communications to connect to sensor
devices from which environmental data can be collected.
Furthermore, the USB (Type-A) port can connect to both
memory storage media and a webcam for obtaining image
data. It comes with a built-in microSD card slot as standard
for recording and storing equipment status changes anderror log data.
It is also equipped with MQTT(3) communication andauthentication functions to facilitate connection to cloudFig. 1 The SANMOTION C S200 motion controller

33

SANYO DENKI Technical Report No.56 November 2023

systems for storing the recorded data.

Development of the SANMOTION C S200 Motion Controller

Table 1 General specifications
Items

Advanced model
Basic model
EtherCAT (100 Mbps) master function, FoE-compatible
Ethernet (10/100/1000 Mbps) protocols (Modbus TDP, OPC UA, Ethernet/IP)
Interface
RS-485 (9600 to 115200 bps), 1-Wire (15400 bps, half-duplex bidirectional communication)
USB 2.0: Type A (for memory storage and webcam), Mini-B (for PC)
MicroSD card slot (up to 32 GB)
Digital input: 16 points, 24 VDC, positive/negative common input
Digital input/output
Digital output: 8 points, 24 VDC, 0.5 A/point, sinking output
Analog output
Analog output: 2 points, output range 4 to 20 mA, resolution 4000
19.2 to 30 VDC, 0.9 A (main power supply)
Input power supply
19.2 to 30 VDC, 140 mA or more (I/O power supply)Power consumption
22 W
Cooling method
Passive air cooling55 × 120 × 110 mm
Dimensions (W × H × D)
Mass
300 g
Sequence control
Motion control
Sequence control
Control functions(Electronic cam and gear, linear interpolation, circular interpolation)
Motion control (PTP control)
Robot control: CNC function(Cartesian coordinate, SCARA, parallel link)
Programming languages conforming to international standard (IEC 61131-3)
Control language
G-code (complies with DIN 66025)–
Web-based data visualization(4)Edge Gateway
MQTT protocol
Network functions
Email notification (SMTP protocol)
Web-based application
UL 61010-1, 3rd Ed., UL 61010-2-201, 2nd Ed.
UL/cULCSA C22.2 No. 61010-2-201:18, 2nd Ed., CSA C22.2 No. 61010-1-12, 3rd Ed.
Compliance
EMC Directive EN 61131-2:2007
with standards
UKCA MarkEN 61131-2:2007
KC Mark
KS C 9610-6-4:2017, KS C 9610-6-2:2019

Factory

Remote location
Internet

Internet
Cloud
PC

RouterRouterGateway

Factory LAN

Monitor/Change programs
Check/Correct/Update
programs

Browser-based status monitoringand setting of controller
Data storage

Integrated development
softwaremicroSD
Check images when an error occurs
Detect error in real time

Via web-based datavisualization

New productWeb-based application

WebcamEmail notification
Temperature/
Humidity

SensorServo system

Fig. 3 System configuration

SANYO DENKI Technical Report No.56 November 2023

34

The new product features a remote maintenance and an
email notification to inform users of detailed information in
the event of equipment failure.
T he new pro duc t c ompl ies w it h t he fol low i ng
international standards: UL/cUL (North America), EMC
Directive (Europe), UKCA Mark (United Kingdom), andKC Mark (South Korea).
(2) 1-Wire is a communication bus protocol for transferring datausing only a ground wire and a single signal/power line.
(3) MQT T, or Message Queuing Telemetr y Transpor t, is alightweight communication protocol suitable for frequentsending and receiving of TCP/IP-based short messages.
(4) A drawing tool feature for designing screens on a web browser.

[microSD]
Data storage[Diagnosis
display][USB host function]
Connect to webcam[USB device function][RS-485,
1-Wire communication]
Collect environmental data

[Digital I/O]
[Analog
output][Input power][Ethernet]
Connect to cloudand peripheral devices[EtherCAT communication]
Connect to servo system

Fig. 4 Interface for data collection and storage

3. Features
This new product maintains the same dimensions andmass as the industry’s smallest-in-class(5)(1) Example of setting “Axis X” as motor axis

SANMOTIONC S100 with the addition of IoT capabilities. It can collectand store image data and environmental data of theequipment in real time while simultaneously performing
motion control. It is also now possible to remotely monitor
the equipment status and perform maintenance thanks tothe connections to Automation Server(6) or a cloud system.
Moreover, it allows users to check the status of the new
product and set parameters from a web browser. The details(2) Set Axis X to the “AXIS_DATA_RECORD” program command
to record axis information.

of each function are provided below.

3.1 Data collection and storage
Figure 4 shows the interface designed for data collection
and storage. The new product can collect time-series data

(3) Axis X information is collected and recorded on a microSD card.

on connected servo systems, digital input/output, andenvironmental conditions. It can easily collect and store
servo system position and status information by simply
specifying the applicable motor axes in the program (seeFigure 5). The new product stores the collected data on its
built-in storage (32 GB) or a microSD card (max. 32 GB),enabling users to check the operation status of equipment
over a long period. The new product also records the status asStored data example• Current position of Axis X• Commanded position of Axis X• Status of Axis X

Fig. 5 Collecting and storing information on servo
system axes

an image by connecting to a webcam. For example, when anerror occurs, the new product records images before and after
the error, enabling prompt identification of the root cause.

3.2 Remote status monitoringand maintenance functions
As shown in Figure 6, the new product can establish
c o m mu n i c at io n w it h a re m ot e c o m put er t h rou g hAutomation Server. The Edge Gateway is a function forconnecting a computer to the new product via Automation
Server. It has been incorporated into the new product andthe integrated development tool (software for programmingand configuring the servo system).

35

SANYO DENKI Technical Report No.56 November 2023

Development of the SANMOTION C S200 Motion Controller

Edge Gateway supported

Edge Gateway supported

by integrated development toolby new productInternet

Program monitoring

Internet
Automation
ServerNew product

PC

Internet

Remote control of motion controller

Internet
Automation
ServerPC

Fig. 6 Remote control of motion controller

図版の文字

123

Users can check the program variables of the new productFig. 8 Remote monitoring of 英語版用
programs
Condens

by using the dashboard function of the Automation Server.
Furthermore, since users can operate the new productremotely by connecting to a VPN,(7) they can monitor andmodify programs without actually visiting the work site.

New
product

英語版用Times Ten

3.3 Email notification

Figure 9 shows the notification process flow in the event ofequipment abnormalities.
Its email notification function uses the
SMTP（a）
従来品 protocol,（b）
開発品(5) Based on our research comparing IoT-ready motion controllers
for 8-axis control (as of August 2023).
(6) The name of the cloud service provided by CODESYS for
remotely operating controllers.
(7) VPN, or Virtual Private Network, is a technology for connecting
locations with dedicated virtual lines and securely exchanging
information.

promptly informing the administrator when equipment
errors are detected. Notifications can be set not only forerrors but also for production conditions, such as when theplanned production volume is reached. This enables theadministrator to check the production status without being
physically present on-site.

3.2.1 Remote status monitoring
To monitor the equipment status from remote locations,users can use the dashboard to check the collected data,

This feature allows the administrator to monitor theequipment and production status in real time, ensuring
efficient, stable production.

including the position of each axis, error information, andthe digital signal status, as shown in Figure 7. Furthermore,users can grasp the equipment status by checking therunning program variables in the new product.

Internet

Personin charge

SMTP
server

ProblemoccurredInternet
SMTP
communication

Emailnotification

New
product

Equipment

Fig. 9 Email notification

Fig. 7 Dashboard

3.4 Connecting to cloud services
As shown in Figure 10, the new product performs
communication using the MQTT protocol and implements

3.2.2 Remote maintenance
Users can monitor and modify programs, as shown in
Figure 8, from remote locations by connecting the integrated
development tool and the new product via the Automation

authentication functions to connect to cloud systems.
Security certificate and private key files can be configured
from the screen shown in Figure 11 using a web browser.
This function enables quick connection to cloud systems.

Server’s VPN. This enables users to perform maintenanceon the new product from anywhere at any time, reducing therecovery time in case of equipment abnormality.

SANYO DENKI Technical Report No.56 November 2023

36

Private
key Certificate

Public key

Authentication

MQTT communication
User’scloud system
Internet

New productFig. 10 Connecting to cloud system

Table 2 Status check items
Monitored items

FunctionController
information

Device name, serial no., etc.

StatusCPU usage, memory usage, etc.

Network settings

Ethernet and WLAN IP address, etc.

Digital/Analog
signalStatus of input/output signals

1-wire device
in connection

Information of connected
図版の文字 device

Log data

Program running status

WebcamCondens
Monitoring with live
streamingand images
英語版用Service startup
statusTimes Ten
Status check of Edge
Gateway
and others

123

英語版用

（a）従来品（b）
開発品

Fig. 11 Settings screen of certificate and private
key files

3.5 Browser-based status display
and settings
The new product provides improved usability with its
web-based applications, which enable users to check thecontroller status and adjust settings on a web browser.

3.5.1 Product status display
Table 2 shows the status items to monitor, and Figure 12
shows the corresponding status display screen. Users can

Fig. 12 Status display screen for the new productcheck the product’s device name, serial number, version
information, and the Ethernet port settings. Additionally,
the new product has a feature to graphically display its status
including CPU load and memory usage in real time. Thisfeature can be used to check the performance of the new
product and to help troubleshoot problems in the event ofabnormal CPU load level fluctuations.

3.5.2 Setting parameters
Table 3 shows the configurable parameters for the new
product.
The new product allows users to configure network
settings using a web browser instead of dedicated software,

Users can check the storage space of the new product andunlike previously. Users can also specify the sender andthe capacity and storage usage of a microSD card, preventing

recipient email addresses on the email settings screen

data storage errors caused by insufficient storage space.

and check the email-sending status as shown in Figure 13.
Additionally, the parameter setting screen for the webcam,
shown in Figure 14, enables users to adjust the camera
settings while viewing the images.

37

SANYO DENKI Technical Report No.56 November 2023

Development of the SANMOTION C S200 Motion Controller

Table 3 Setting parameters
Setting
parameters

Function

Network settings

Settings of Ethernet and WLAN IP
address, etc.

Notification
email settings

Destination settings, send test email

Webcam settings

Setting of contrast and otherparameters

Service startup
settings

Automatic startup settings of Edge
Gateway and other services

4. Conclusion
In this article, we introduced the SANMOTION C S200
motion controller and described some of its features.
The following is a brief summary of the new features it offers.
• Can collect and store equipment data in real time. Users

can quickly identify the cause of problems by using stored
abnormality data for failure analysis.
• Employs Edge Gateway that connects the new productto remotely located computers via Automation Server.
Automation Ser ver’s dashboa rd enables remotemonitoring of equipment status. Furthermore, users canremotely perform equipment maintenance via a VPN,
reducing the recovery time in the event of failure.
• C an send notification emails based on error andproduction status, enabling users to quickly understandequipment status and production conditions, helping

Fig. 13 Sent email status

maintain stable, efficient production.
• I mproved in usability by featuring browser-based statusmonitoring and settings application.
SANMOTION C S200 is a motion controller designed
to detect changes in the operating status and ambientenvironment of equipment, promptly notifying usersof the status. It collects and stores error log data in realtime, minimizing recovery time in the event of a failure.
Furthermore, it contributes to improving the productivity ofequipment by enabling users to remotely monitor the operating
status of equipment and perform maintenance when necessary.
Moving forward, we will continue to leverage IoT and digitaltechnologies to develop products that help create new value forour customers.
Note: The company names, product names, and network protocol
names mentioned in this article are the trademarks orregistered trademarks of their respective owners.
Reference(1) Hideaki Kodama and 7 others: “Development of the
SANMOTION C SMC100 Motion Controller”
SANYO DENKI Technical Report No. 47, pp. 30-34 (2019.5)

Fig. 14 Webcam settings screen

SANYO DENKI Technical Report No.56 November 2023

38

Development of the SANMOTION C S200 Motion Controller

AuthorTatsuya Okazaki
Design Dept. 2, Servo Systems Div.
Works on the design and development of system products.

Tomonobu Tazaki
Design Dept. 2, Servo Systems Div.
Works on the design and development of system products.

Hiroto Endo
Design Dept. 2, Servo Systems Div.
Works on the design and development of system products.

Masayuki Mizutani
Design Dept. 2, Servo Systems Div.
Works on the design and development of system products.

Yoshitaka Kobayashi
Design Dept. 2, Servo Systems Div.
Works on the design and development of system products.

Hyukjun Kwon
Design Dept. 2, Servo Systems Div.
Works on the design and development of system products.

Shigeki Sato
Design Dept. 2, Servo Systems Div.
Works on the design and development of system products.

39

SANYO DENKI Technical Report No.56 November 2023

56

November2023

https://www.sanyodenki.com/

Published in Japan on November 15, 2023 by SANYO DENKI CO., LTD.
Published semi-yearly
3-33-1 Minami-Otsuka, Toshima-ku, Tokyo 170-8451, Japan
Phone +81 3 5927 1020
Publisher Nobumasa Kodama
Editorial Board Members:
Satoru Onodera
Editor-in-Chief
Yasutaka Narusawa
Managing Editor
Takashi Kobayashi
Secretariat
Shiho Tsukada
Secretariat
Risa Inamura
Secretariat
Kakuhiko Hata
Sho Matsushita
Hiroshi Sakaba
Makoto Ishida
Daigo Kuraishi
Yoshiyuki Usui
Hitoshi Yoshiike
Rieko Komine
Copyright © 2023 SANYO DENKI CO., LTD.
All rights reserved.
No part of this publication may be reproduced in any manner whatsoever without written
permission from SANYO DENKI.
All company and product names used in this publication are trademarks or registeredtrademarks of their respective companies.